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Honeywell DVD Recorder L User's Manual

1. PLUG IN MICROCOMPUTER FLAME AMPLIFIER TEST RELAY DRIVE RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS CIRCUIT SAFETY RELAY CIRCUIT lt STATUS LEDs CONTROL POWER SUPPLY POWER R1 R1 RUNNING 2 PRE IGNITION LOCKOUT LIMITS CONTROLLER INTERLOCK INTERLOCK 1 ru HA RB ro Ri Lenton OEE 2 LOW FIRE SWITCH 6K1 3K1 HIGH FIRE KEYBOARD DISPLAY MODULE 8K1 COMMON 4 INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS 8 2 MODULATE 9K1 LOW FIRE FIELD WIRING INTERNAL WIRING 1 DDL zj 2 COMMUNICATIONS RESET PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED M23320 Fig 5 Internal block diagram of the R7140G1000 See Fig 8 for detailed wiring 66 1153 03 10 120 Vac 50 60 Hz CONFIGURATION JUMPERS TEST FLAME SIGNAL RUN TEST SWITCH PLUG IN MICROCOMPUTER FLAME Teg AMPLIFIER m CONTROL POWER SUPPLY CONTR PRE IGNITION INTERLOCK 4 RUNNING LOCKOUT LIMITS CONTROLLER INTERLOCK Ed R7140G L M BURNER CONTROL MODULES L1 HOT L2 A 1K1 2K1 5K1 HH 3 IGNITION PILOT V2 MAIN VALVE BLOWER LOW FIRE SWITCH HIGH FIRE 2 8K1 T COMMON t INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS 8 2 MODULATE 9K2 9K1 FIELD WIRING
2. 12 R7140G L L1 8 15 L2 Firing rate motor drives open 1 High Fire Purge Switch and line voltage at terminal 15 after 2 Firing rate motor and transformer 10 11 motor is in High Fire position 13 R7140L L1 8 15 L2 Firing rate motor drives closed 1 Low Fire Start Switch and zero volts at terminal 15 after 2 Firing rate motor and transformer 14 11 motor starts driving closed 14 R7140G L 11 12 1 Raise setpoint of Series 90 1 Series 90 Controller controller firing rate motor 2 Firing rate motor and transformer should drive toward open 2 Lower setpoint of Series 90 controller firing rate motor should drive toward closed 15 R7140M with 14 11 If damper motor is used motor Damper motor open damper drives damper open contacts 16 R7140M with 11 8 13 L2 If damper motor is used motor 1 Low Fire Start Switch open damper drives open line voltage at 2 Damper motor contacts terminal 13 after motor is in Low Fire position 17 R7140M with 11 8 13 L2 If damper motor is used motor 1 Low Fire Start Switch open damper drives open zero volts at 2 Damper motor contacts L1 11 terminal 13 Final All N CAUTION Equipment Damage Hazard Improper wiring can damage equipment On completing these tests open the master switch and remove all test jumpers from the subbase terminal Also remove bypass jumpers from the low fuel pressure limits if used to prevent equipment da
3. Internal system fault occurs Purge card is removed Purge card is bad 5 MAIN FLAME ESTABLISHING Period MFEP a Low Fire Switch Opens b Lockout Interlock opens R7140L 23 R7140G L M BURNER CONTROL MODULES Ignition pilot valve intermittent pilot valve terminal is not energized Main valve terminal is not energized No flame is present at the end of MFEP Internal system fault occurs Purge card is removed Purge card is bad UN Period No flame is present Lockout Interlock opens R7140L Interrupted pilot valve terminal is energized R7140G M Main valve terminal is not energized Internal system fault occurs Purge card is removed Purge card is bad OSTPURGE Period Pre Ignition Interlock does not close in five seconds and opens after five second time period Ignition pilot valve intermittent pilot valve terminal is energized Main valve terminal is energized Internal system fault occurs Purge card is removed Purge card is bad OPERATION v yar roa moog Sequence of Operation The R7140 has the following operating sequences see Fig 4 9 and 14 The R7140 LED provides positive visual indication of the program sequence POWER PILOT FLAME MAIN and ALARM Note The Power LED is lit for 4 1 2 seconds and off for 1 2 seconds to indicate normal operation Initiate The R7140 enters the INITIATE sequence when the Relay Module is powered The R7140 can al
4. terminals 5 6 and 18 are energized a The R7140G has an interrupted or intermit tent pilot valve terminal 6 depending on the selection of configuration jumper 2 b The R7140L has a 15 second interrupted pilot valve terminal 6 c The R7140M has an intermittent pilot valve terminal 6 NOTE of the R7140s have a ten second interrupted pilot valve ignition terminal 5 2 During PFEP the Low Fire Switch must remain closed If it opens a safety shutdown occurs 3 The Pre Ignition Interlock input is ignored throughout the Ignition Trial state b Flame must be proven by the end of the 10 second PFEP four if JR1 is clipped to allow the sequence to continue If flame is not proven by the end of PFEP a safety shutdown occurs c After five seconds the ignition terminal 18 is de energized for early spark termination 66 1153 03 24 2 Main Flame Establishing Period MFEP a Terminal 7 is energized when the presence of flame is verified at the end of a 10 second Pilot Flame Estab lishing Period PFEP four seconds if JR1 is clipped b Terminal 5 is turned off 10 seconds after terminal 7 is energized c Terminal 6 action 1 R7140L De energized 15 seconds after terminal 7 is energized 2 R7140G a Not turned off or b 15 seconds after terminal 7 is energized and JR2 is clipped or c 30 seconds after terminal 7 is energized and terminals 8 and 15 are jumpered and jumper JR2 is clipped
5. contacts 8 30 seconds with JR2 clipped and jumper from terminal 8 to terminal 15 STANDBY and RUN can be an infinite time period PURGE will be determined by which ST7800A purge card is selected 15 timings are available from 2 seconds to 30 minutes IMPORTANT NOTE Allowable inrush can be up to ten times the pilot duty rating EXAMPLE Pilot duty rating 50 VA At 120 V running current is 50 120 0 42A Maximum allowable inrush is ten times 0 42A 4 2A INSTALLATION When Installing this Product 1 Read these instructions carefully Failure to follow them could damage the product or cause a hazardous condition 2 Check the ratings given in the instructions and marked on the product to make sure the product is suitable for the application 3 Installer must be a trained experienced flame safeguard service technician 4 After installation is complete check out the product operation as provided in these instructions A WARNING Fire or Explosion Hazard Can cause property damage severe injury or death To prevent possible hazardous burner operation verify safety requirements each time a control is installed on a burner A WARNING Electrical Shock Hazard Can cause serious injury or death Disconnect the power supply before beginning installation More than one power supply disconnect may be required 66 1153 03 1 Wiring connections for the relay modules are
6. 3 R7140M Remain energized as long as call for heat is present Run 1 Fifteen seconds after the main valve terminal 7 is energized and flame is maintained the R7140 goes to Run 2 The firing rate motor releases to modulation R7140G L Damper motor is energized R7140M 3 The R7140 is now in RUN and remains in RUN until the controller input terminal 16 or 4 model dependent opens indicating that the demand is satisfied or a limit opened Postpurge The R7140 provides a 15 second POSTPURGE following the completion of the RUN period call for heat ends The blower motor output remains powered to drive all products of combustion and any unburned fuel from the combustion chamber It also supplies combustion air to burn fuel being purged from the fuel line downstream of the fuel shutoff valve 1 The main fuel valve and intermittent pilot valve terminals 7 and 6 are de energized and the firing rate motor is commanded to the low fire position to begin the POSTPURGE period 2 Afterthe 15 second POSTPURGE period is completed the blower motor terminal 8 is de energized and the R7140 reenters Standby Run Test Switch A WARNING Explosion Hazard Can cause serious injury or death Do not use the Run Test switch during the Pilot Flame Establishing Period for the R7140 when using Direct Spark Function because it turns on the main gas valve causing an accumulation of fuel in the burner The Run Test Switch is loca
7. 7044 ULTRAVIOLET SERIES 90 FLAME DETECTOR SERIES 90 CONTROLLER FIRING RATE MOTOR C7061 C7927 OR ELLow Soo z ee C7076A D L1 HOT ULTRAVIOLET 120 60Hz 11 HOT FLAME DETECTOR POWER supply e O j MASTER SWITCH 124 C7061 OR C7076 MUST BE RATED FOR 120 V 60Hz TWO DETECTORS OMM AS one PET MEANS ND OVERLOAD WITH THE SAME MODEL NUMBER CAN BE WIRED IN PARALLEL TO THE SAME TERMINALS C7076A D DOES NOT HAVE LEADWIRES FOR INSTRUCTIONS SEE FORM NUMBERS 60 2046 FOR C7012A MODELS USE AEL NEG GEASSAEWIRING WITH ELECTRON TUBES 60 2044 FOR C7012A C E F SOLID STATE FOR DIRECT SPARK IGNITION OIL OR GAS CONNECT THE IGNITION MODELS 95 8269 FOR THE C7076A TRANSFORMER AND MAIN FUEL VALVE S AS SHOWN IN INSET VIETE SH TTERIREADWIRES ARE GNI eT ULTRAVIOLET FLAME DETECTORS C7076A D ADJUSTABLE SENSITIVITY FOR THE C7015A INFRARED LEAD SULFIDE FLAME DETECTOR EITHER LEADWIRE CAN BE CONNECTED TO THE F TERMINAL RUN THE C7015A ULTRAVIOLET FLAME DETECTORS DO NOT HAVE LEADWIRES LEADWIRES ALONE IN CONDUIT ALL THE WAY TO THE WIRING SUBBASE TERMINAI ZIS USED ONI KFOR THE SHUTIER ON SELF CHECKING AND GROUND THE CONDUIT AT THE SUBBASE REFER TO PUBLICATION 60 2306 FOR DETAILED INSTRUCTIONS M22610 Fig 12 Sample block diagram of field wiring for the R7140L1009 used for replacing R4140L Programmers with pre ignition interlocks 17 66 115
8. C7011 Check 2 3 Holders Complete Assemblies C7008 C7009 Q179 Dynamic Ampli R7847B 9 2 8 Gas oil Ultraviolet Purple C7012A C Check amp coal Peeper Dynamic n7g47c h 3 Gas oil Ultraviolet Purple C7012E F Check coal Peeper Infrared Red No R7848A 2 3 Gas oil Infrared Lead Sulfide 7015 coal Dynamic Ampli R7848B9 2 3 Gas oil Infrared Lead Sulfide 7015 Check coal Red R7852A 2 3 Gas oil Infrared Lead Sulfide 7915 White coal Dynamic Ampli R7g52B 2 3 Gas oil Infrared Lead Sulfide 7915 Check coal Ultraviolet Purple No R7849A 0 8 1 or Gas oil Ultraviolet C7027 C7035 C7044 2 3 Minipeeper Dynamic Ampli R7849B9 0 8 1 or Gas oil Ultraviolet C7027 C7035 C7044 Check 2 3 Minipeeper Dynamic Self 57861 0 8 1 Gas oil Ultraviolet C7061 Check 2 3 coal Blue Dynamic Self R7gg6a e 2 3 Gas oil Ultraviolet Adjustable C7076 Check coal Sensitivity Optical White Dymanic Ampli R7851B 0 8 1 or 2 3 Gas oil Optical UV Visible C7927 C7962 Check amp coal Light Dynamic Self R7g51c 2 3 Gas oil Optical UV only C7961 Check coal Flame Failure Response Time FFRT depends on selection of amplifier and 7800 SERIES and R7140 Relay Module gt R7824C is used only with the 24 Vdc RM7824 Relay Module and C7024E F Flame Detectors Circuitry tests all electronic components in flame detection system amplifier and detector
9. Dissipation in the Run Mode 10W maximum Maximum Total Connected Load 2000VA Fusing Total Connected Load 15A fast blow type SC or equivalent Environmental Ratings Ambient Temperature Operating 40 F to 140 F 40 C to 60 C Storage 40 F to 150 F 40 C to 66 C Humidity 85 relative humidity continuous noncondensing Vibration 0 5G environment Weight With Dust Cover and Q520A Subbase 4 Ib 5 oz 1 96 kg Dimensions See Fig 2 Approvals Underwriters Laboratories Inc UL cULus Component Recognized Federal Communications Commission Part 15 Class A Emissions Mounting Q520A 20 terminal Subbase for panel mounting Required Components Plug in Flame Signal Amplifier See Table 1 Plug in Purge Timer Cards See Table 2 R7140G L M BURNER CONTROL MODULES Table 1 Flame Detection Systems Plug in Flame Signal Amplifiers Applicable Flame Detectors Flame Failure Response Type Color Self Checking Model Time sec Fuel Type Models Rectification Green Dymanic Self n7go4cbch 3 Gas oil Ultraviolet Purple C7024E F Check coal Peeper No R7847A9 0 8 1 or 2 3 Gas Rectifying Flame Rod C7004 C7007 C7011 Holders Complete Assemblies C7008 C7009 Q179 No 7847 9 2 3 Gas oil Ultraviolet Purple C7012A C coal Peeper Dynamic Ampli R7847B 9 0 8 1 or Gas Rectifying Flame Rod C7004 C7007
10. No 18 stranded for example See Fig 13 7 Strip the insulation nearest the ignitor and ground it also strip the insulation nearest the ignition transformer and ground it 8 Ifthe problem cannot be eliminated consider changing the system to an ultraviolet flame detection system IGNITION TRANSFORMER IGNITION BURNER ASSEMBLY LEAD d BURNER J MODULE FLAME ROD LEAD M19423B Fig 20 Eliminating ignition interference Hot Refractory Saturation Test All Infrared Detectors Start the burner and monitor the flame signal during the warm up period A decrease in signal strength as the refractory heats up indicates hot refractory saturation If saturation is extreme the flame signal drops below 1 25 Vdc and the system shuts down as though a flame failure occurred 66 1153 03 R7140G L M BURNER CONTROL MODULES If hot refractory saturation occurs the condition must be corrected Add an orifice plate in front of the cell to restrict the viewing area lengthen the sight pipe or decrease the pipe size diameter Continue adjustments until hot refractory saturation is eliminated Hot Refractory Hold in Test Rectifying Photocell Infrared Detectors Ultraviolet Detectors This condition can delay response to flame failure and also can prevent a system restart if hot refractory is detected Infrared lead sulfide detectors can respond to infrared rays emitted by a hot refractory
11. Normal Operation Check the Items Listed Below 6 All L1 5 1 Ignition spark if ignition 1 Watch for spark or listen for buzz transformer is connected to a Ignition electrodes are clean terminal 5 b Ignition transformer is okay 2 Automatic pilot valve opens if 2 Listen for click or feel head of valve for connected to terminal 5 activation a Actuator if used NOTE Refer to wiring dia b Pilot valve gram of system being tested 7 L1 6 Same as test 6 for Same as test no 6 If using direct spark connections to terminal 5 If ignition check the first stage fuel valve s using direct spark ignition check instead of the pilot valve the first stage fuel valve s instead of the pilot valve 8 L1 7 Automatic main fuel valve s 1 Listen for and observe operation of the open main fuel valve s and actuator s If using direct spark ignition on a 2 Valve s and actuator s model with intermittent pilot on terminal 6 check the optional second stage fuel valve if used 9 L1 9 Alarm if used turns on 1 Alarm 10 R7140G L L1 8 13 L2 Firing rate motor drives open 1 Low Fire Start Switch and zero volts at terminal 13 after 2 Firing rate motor and transformer 10 11 motor starts driving open 11 R7140G L L1 8 13 L2 Firing rate motor drives closed 1 Low Fire Start Switch and line voltage at terminal 13 after 2 Firing rate motor and transformer 14 11 motor is in Low Fire position
12. Read the voltage between the subbase wiring terminals voltage is present on most terminal connections listed in the Voltmeter column when power is on 8 Ifthere is no voltage or the operation is abnormal check 3 Open the master switch before installing or removing a jumper on the subbase 4 Before continuing to the next test be sure to 9 remove test jumper s used in the previous test 5 Replace all limits and interlocks that are not operating properly Do not bypass limits and interlocks 10 N CAUTION n Equipment Damage Hazard Improper testing can damage equipment 12 Internal surge protectors can break down and conduct a current causing the R7140 to fail the dielectric test or possibly destroy the internal lightning and high current protection Do not perform a dielectric test with the R7140 installed the circuits and external devices as described in the last column Check all wiring for correct connections tight terminal screws correct wire and proper wiring techniques Replace all damaged or incorrectly sized wires Replace faulty controllers limits interlocks actuators valves transformers motors and other devices as required Make sure normal operation is obtained for each required test before continuing the checkout After completing each test be sure to remove the test jumper s WARNING Explosion Hazard Can cause serious injury or death Equipment Recommended Make sure all manual fuel shut
13. a jumper wire between terminals 15 and 8 SERVICE NOTE Clipping and removing these site configurable jumpers enhances the level of safety Removal after 200 hours of main valve operation will result in a hard lockout Code 110 25 66 1153 03 R7140G L M BURNER CONTROL MODULES STATIC CHECKOUT After checking all wiring perform this checkout before installing the R7140 on the subbase These tests verify the Q520A Wiring Subbase is wired correctly and the external controllers limits interlocks actuators valves transformers motors and other devices are operating properly 3 When jumpered to Ignition Pilot and Main Valves use ammeter in series and verify proper current draw General Instructions 1 Perform all applicable tests listed in Static Checkout Table 8 in the order listed 2 Make sure all manual fuel shutoff valve s are closed 3 Perform only those tests designated for the specific R7140 model being tested A WAR N NG 4 Raise the setpoint of the operating controller to simulate Explosion and Electrical Shock Hazard a call for heat Can cause serious injury death or equipment 5 For each test open the master switch and install the damage jumper wire s between the subbase wiring terminals 1 Close all manual fuel shutoff valve s before starting listed in the Test Jumpers column these tests 6 Close the master switch before observing operation 2 Use extreme care while testing the system Line 7
14. even when the refractory has visibly ceased to glow Infrared radiation from a hot refractory is steady but radiation from a flame has a flickering characteristic The infrared detection system responds only to flickering infrared radiation it can reject a steady signal from hot refractory The refractory steady signal can be made to fluctuate if it is reflected bent or blocked by smoke or fuel mist within the combustion chamber Be careful when applying an infrared system to verify its response to flame only The ultraviolet detector can respond to hot refractory above 2300 F 1371 C 1 Operate the burner until the refractory reaches its maximum temperature Infrared Only If the installation has a multi fuel burner burn the heavier fuel that is most likely to reflect bend or obscure the hot refractory steady infrared radiation 2 When the maximum refractory temperature is reached close all manual fuel shutoff valves or open the electrical circuits of all automatic fuel valves 3 Visually observe when the burner flame or FLAME LED goes out If this takes more than three seconds the infrared detector is sensing hot refractory 4 Immediately terminate the firing cycle Lower the setpoint to the operating controller or set the Fuel Selector Switch to OFF Do not open the master switch NOTE Some burners continue to purge oil lines between the valves and nozzles even though the fuel valves are closed Terminating the firing
15. gas flow Make sure the main fuel is shut off just upstream from the burner inlet or disconnect power from the automatic main fuel valve s Close the master switch and start the system with a call for heat by raising the setpoint of the operating controller see the relay module sequence The R7140 Relay Module should start a ten second INITIATE sequence Let the sequence advance to PILOT IGN status is displayed on the Keyboard Display Module if used PILOT LED turns on ignition spark should occur and the pilot should light If the pilot ignites the FLAME LED is energized Go to step 7 If the pilot flame is not established in ten seconds four seconds if configuration jumper JR1 is clipped safety shutdown occurs Let the sequence complete its cycle Push the reset push button and let the system recycle once If the pilot still does not ignite make the following ignition pilot adjustments a Open the master switch and remove the R7140 Relay Module from the subbase b On the subbase jumper L1 to the ignition terminal refer to the appropriate wiring diagram to determine the proper terminal Disconnect the leadwire to the pilot valve if it is connected to the same terminal c Close the master switch to energize only the ignition transformer d If the ignition spark is not strong and continuous open the master switch and adjust the ignition electrode spark gap setting to the manufacturer recommendation e Mak
16. the setpoint of the operating controller Observe that the pilot is established during PILOT IGN and the main burner flame is established during MAIN IGN within the normal lightoff time Measure the flame signal Continue to check for the proper signal through the RUN period Check the signal at both High and Low Firing Rate positions and while modulating if applicable 9295p 66 1153 03 R7140G L M BURNER CONTROL MODULES 20 Run the burner through another sequence observing the flame signal for a Pilot flame alone b Pilot and main flame together c Main flame alone unless monitoring an intermittent pilot Also observe the time it takes to light the main flame Ignition of main flame should be smooth 21 Make sure all readings are in the required ranges before proceeding 22 Return the system to normal operation NOTE After completing these tests open the master switch and remove all test jumpers from the subbase terminals limits controls or switches Direct Spark Ignition Systems This check applies to gas and oil burners not using a pilot It should immediately follow the preliminary inspection Refer to the appropriate sample block diagram of field wiring for the ignition transformer and fuel valve s hookup NOTE Low fuel pressure limits if used could be open If so bypass them with jumpers during this check 1 Open the master switch 2 Complete the normal ready to fire checkout of the fuel
17. 0 15 ONLY PREPURGE LOW FIRE JR1CLIPPED MFEP RUN POSTPURGE STANDBY Power Power Power Power Power Power OPitor OPitor OFLAME OFLAME FLAME FLAME MAIN Oman ALARM QALARM O ALARM l L L F lt 5 lla Lz fL L C j x OGY 7X RUNNING INTERLOCKS CLOSED CLOSED R7140M SWITCHING N 2 LOW FIRE SW V SAFE START CHECK FLAME PROVING mm 44 OA A WHEN USING A SPRING RETURN ACTUATOR MOTOR REMOVE J1 AND J2 JUMPERS LOCATED ON R7140M SUBBASE A PII MEANS PRE IGNITION INTERLOCK A R7140M WHEN USED AS BC7000 REPLACEMENT ON R4140 WITH START INTERLOCKS L1 TO 16 M23331B Fig 14 Operating sequence R7140M 19 66 1153 03 R7140G L M BURNER CONTROL MODULES START INTERLOCKS ye LIMITS k db GO CONTROLLER 2K1 5K1 Rd e ene ere See I I AIRFLOW _ _ _ _ 1 PILOT i I 15 SECOND 4inteRMirtent 5 PILOT VALVE MAIN VALVE Sal M23335 9K2 CONFIGURATION JUMPERS 3K omm 6K1 BLOWER 5 LF I IG
18. 1062 X R4140M1103 M1111 A1039 X R4140M1145 M1152 A1047 X R4140M1160 M1178 A1062 X R4140M1186 A1047 X R4140M1194 ST7800A1062 BC7000L1000 w PM720M2002 ST7800A1062 X BC7000L1000 w PM720M2036 i X Check terminal 8 and 15 If jumpered ST7800A1031 7 second purge If not jumpered ST7800A1039 30 second purge Mounting R7140 Relay Module Installing the Programmer Fig 3 A WARNING Electrical Shock Hazard Can cause severe injury death or property damage Disconnect power before installation to prevent electrical shock More than one disconnect may be involved 1 Open the master switch 2 Make sure no subbase wiring is projecting out beyond the terminal blocks Tuck in wiring against the back of the subbase so it does not interfere with the contacts 3 Grasp the programmer chassis and engage the chassis hinge brackets with the pivot pins at the bottom of the subbase 4 Swing the chassis inward until the spring connectors engage the knifeblade contacts Push in until the contacts are fully engaged 5 Tighten the chassis retaining screw securely 6 Close the master switch to restore power 66 1153 03 8 Removing the Programmer RONA Open the master switch Loosen the chassis retaining screw Pull outward on the top of the chassis Disengage the chassis hinge brackets from the subbase pivot pins KNIFE BLADE CONTACTS 20 SPRING CONNECTORS CHASSIS RETAINING Es
19. 12 times a minute during burner operation and shuts down burner if detection system fails 9 Circuitry tests flame signal amplifier 12 times a minute during burner operation and shuts down burner if amplifier fails 200 220 240 Vac applications require a 120 Vac 10 VA minimum stepdown transformer not provided to drive the shutter Applies to R7886A series 2 or greater R7861 series 1 or greater Fig 2 shows flame detector wiring f Use C7027 C7035 and C7044 Flame Detectors only on burners that cycle on off at least once every twenty four hours Use C7061A Ultraviolet Detector with R7861A Amplifier or C7076A Flame Detector with R7886A Amplifier as ultraviolet flame detec tion system for appliances with burners that remain on continuously for twenty four hours or longer 9 R7847A B Amplifiers with 0 8 1 second FFRT should NOT be used with C7012A C Solid State Ultraviolet Detectors h R7824C Series 2 and greater and R7847C Series 4 or greater check flame detector system when flame reaches 1 5 Vdc or at 4 5 seconds whichever occurs first NOTE R7824C Series 2 or greater and R7847C Series 4 or greater pulse the shutter when signal of 1 5 Vdc is sensed Display readings of 0 7 to 2 4 Vdc are common i Order flame rod separately see flame detector Instructions for holder 3 66 1153 03 R7140G L M BURNER CONTROL MODULES 57800 1068 Spanish language Table 2 Plug in Purge Timer Cards 57800 1118 Katakana Japanese
20. 3 03 R7140G L M BURNER CONTROL MODULES FOR DIRECT SPARK IGNITION OIL OR GAS IGNITION TRANSFORMER MAIN FUEL VALVE 5 5 SECOND IGNITION WIRING A SUBBASE EARLY SPARK LOCKOUT TERMINATION STRIPA INTERLOCKS INCLUDING AIRFLOW SWITCH RUSTED PREIGNITION PILOT IGNITION INTERLOCKS 15 SECOND INTERRUPTED BURNER CONTROLLER 120V ALARM LIMITS PILOT 9 HIGH FIRE COMMON MAIN FUEL VALVE S BURNER MOTOR BLOWER RECTIFYING FLAME ROD RECTIFYING PHOTOCELL OR INFRARED LEAD SULFIDE FLAME DETECTOR MODULATE Torre _ C7027A C7035A OR SERIES 90 SERIES 90 C7044A ULTRAVIOLET FLAME DETECTOR CONTROLLER FIRING RATE MOTOR C7061 ran 4 ee POWER supply lt 12 MASTER I SWITCH see e I BLACK I I A PROVIDE DISCONNECT MEANS AND OVERLOAD A Naess 1 PROTECTION AS REQUIRED lids erue o s 1 M22611B A USE ALL NEC CLASS 1 WIRING An SOME INSTALLATIONS THE LOW FIRE INTERLOCK IS BETWEEN TERMINALS L1 AND 13 A C7076 COMES WITHOUT LEADWIRES C7061 DOES NOT HAVE BLACK LEADWIRES Fig 13 Block diagram of field wiring for the R7140L2007 used for replacing BC7000L1000 with PM720L 66 1153 03 18 LED DISPLAY BURNER OPERATING CONTROLS AND INTERLOCKS FLAME SIGNAL DAMPER MOTOR R7140G L M BURNER CONTROL MODULES R7140M INITIATE PREPURGE PFEP INITIAL HOLD 10 SEC POWERUP CT MED MpDRIVETO 04 sec 10 20 25 0
21. G MOTOR ACTION FOR R7140L1009 L1 TO 4 4TO3 PII MEANS PRE IGNITION INTERLOCK Fig 9 Operating sequence R7140L1009 and R7140L2007 M23322 L1 HOT 120 Vac 50 60 Hz L2 CONFIGURATION JUMPERS RUN TEST SWITCH MICROCOMPUTER RESET 5 Q DRIVE CIRCUIT STATUS LEDs POWER SUPPLY R1 RUNNING LOCKOUT LIMITS CONTROLLER INTERLOCK 28 RAS gg mla 3 4K1 LOW FIRE SWITCH D HIGH FIRE SWITCH 2 2 6 1 8 DISPLAY MODULE HIGH FIRE O X 8K1 T COMMON 8K2 REMOTE RESET MODULATE 10 9K1 2 DDL 11 LOW FIRE COMMUNICATIONS 12 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED NOTE NUMBERS ON GP201 GP301 SUBBASE PLUG IN PURGE TIMER CARD FLAME SIGNAL R7140G L M BURNER CONTROL MODULES RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS CONTROL POWER R1 2 PILOT MAIN VALVE BLOWER ALARM E gt t INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS FIELD WIRING INTERNAL WIRING M23323 Fig 10 Internal block diagram of the R7140L1009 See Fig 12 for detailed wiring 15 66 1153 03 R7140G L M BURNER CONTROL MODULES L1 HOT L2 CD 120 Vac 50 60 Hz CONFIGURATION PERG De JUMPERS FLAME SIGNAL RUN TEST 4 F SWITCH
22. Internal hardware status monitoring Low Fire Start Switch test Tamper resistant timing and logic Application flexibility 0 80r3 0 second Flame Failure Response Time FFRT depending on amplifier selected Dependable long term operation provided by microcomputer technology Five LEDs for sequence information See Fig 1 Five function Run Test Switch nterchangeable plug in flame amplifiers Nonvolatile memory history files and sequencing status are retained after loss of power and can be viewed using the Keyboard Display Module S7800A1001 sold separately Report generation optional through modbus NOTE Check Service Notes page 7 and Static Check out on page 26 prior to installation of R7140 Burner controller data optional Lockout alarm status Total cycles of operation Total hours of operation Status of configuration jumpers Status of Run Test Switch 66 1153 03 R7140G L M BURNER CONTROL MODULES RUN TEST SWITCH PLUG IN PURGE CARD dL DUST COVER SEQUENCE STATUS van RELAY MODULE RESET FLAME PUSHBUTTON AAACN AMPLIFIER FLAME E d FLAME CURRENT SIMULATOR INPUT TEST JACKS M7552B Fig 1 Burner Control Module and sequence status LEDs SPECIFICATIONS Electrical Ratings See Table 1 Voltage and Frequency 120 Vac 10 15 50 or 60 Hz 1 0 66 1153 03 Power
23. LAME LED light goes out Increase the pilot pressure immediately until the FLAME LED comes on and then turn it down slowly to obtain a pressure reading just above the dropout point or until the flame signal increases to 1 25 Vdc Set the Run Test Switch in the RUN position if used and let the sequence proceed When the MAIN LED turns on make sure the automatic main fuel valve s opens then smoothly open the manual main fuel shutoff valve s or any other manually opened safety shutoff valve s if used and watch for main burner ignition If the main burner flame is established go to step 18 NOTE This step requires two people one to open the 11 12 13 14 15 16 17 18 manual valve s and one to watch for ignition If the main burner flame is not established within five seconds or within the normal lightoff time specified by the equipment manufacturer close the manual main fuel shutoff valve s and open the master switch If the light off is rough the pilot flame size is too small Close the master switch to recycle the burner and stop the sequence in the PILOT period by using the Run Test Switch Increase the pilot flame size by increasing its fuel flow until a smooth main flame is accomplished Reposition the flame scanner sight tube or use orifices until the pilot flame signal voltage is in the range of 1 25 to 1 50 When the main burner lights reliably with the pilot at turndown disconne
24. LOW FIRE INTERNAL WIRING PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED M23321 Fig 6 Internal block diagram of the R7140G2008 See Fig 7 for detailed wiring 11 66 1153 03 R7140G L M BURNER CONTROL MODULES 2ND STAGE FUEL VALVE OPTIONAL I FOR DIRECT SPARK IGNITION OIL OR GAS i IGNITION TRANSFORMER 1 1ST STAGE TO FUEL VALVE LI I I 5 SECOND IGNITION WIRING EARLY SPARK SUBBASE RUNNING TERMINATION ARA INTERLOCKS INCLUDING 10 SECOND AIRFLOW SWITCH INTERRUPTED PILOT IGNITION A PILOT IGNITION PREIGNITION A INTERLOCK S MAIN FUEL VALVE S BURNER MOTOR BLOWER LOW FIRE START SWITCH RECTIFYING FLAME ROD OR INFRARED LEAD SULFIDE FLAME DETECTOR dc MODULATE LOWFIRE C7027A C7035A OR WHITE C7044A ULTRAVIOLET SERIES 90 SERIES 90 FLAME DETECTOR CONTROLLER FIRING RATE MOTOR C7012A C C7061 0R YELLOW C7076A ULTRAVIOLET 120V 60 HZ amp HOT POWER SUPPLY lt 7 FLAME DETECTOR MASTER SWITCH A PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED A USE ALL NEC CLASS 1 WIRING A START INTERLOCKS IF USED BECOME PREIGNITION INTERLOCKS MUST REMAIN CLOSED UNTIL IGNITION TRIALS BEGIN TERMINAL 6 HAS THE FOLLOWING OPTIONS AS RECEIVED INTERMITTENT PILOT JR2 CLIPPED 15 SECOND MAIN FLAME ESTABLISHING PE
25. NITION LIMITS 4 CONTROLLER AIRFLOW 2K1 5K1 IGNXFMR 8 _ _ _ 1 PILOT I 15 SECOND i Jwrenurrewr 5 PILOT VALVE 1 MAIN VALVE ALB M23336 Fig 16 Internal block diagram of the R7140M1007 with pre ignition interlocks See Fig 18 for detailed wiring 66 1153 03 20 R7140G L M BURNER CONTROL MODULES FOR DIRECT SPARK IGNITION OF OIL OR GAS IGNITION 1ST STAGE FUEL VALVE 2ND STAGE FUEL VALVE OPTIONAL WIRING A SUBBASE TERMINAL RUNNING STRIP 4 INTERLOCKS INCLUDING AIRFLOW SWITCH 5 SECOND IGNITION EARLY SPARK TERMINATION 10 SECOND INTERRUPTED PILOT IGNITION CONTROL RECTIFYING FLAME ROD RECTIFYING PHOTOCELL OR INFRARED HZ amp 11 HOT LEAD SULFIDE FLAME DETECTOR MASTER SWITCH C7027A C7035A OR I 1 I C7044A ULTRAVIOLET POWER SUPPLY PROVIDE DISCONNECT MEANS AND I FLAME DETECTOR OVERLOAD PROTECTION AS REQUIRED I I 1 USE ALL NEC CLASS 1 WIRING C7012A E ORF START INTERLOCKS IF USED BECOME PRE IGNITION ULTRAVIOLET INTERLOCKS MUST REMAIN CLOSED UNTIL IGNITION TRIALS BEGIN FLAME DETECTOR PM720M 16 TO 4 IS A PRE IGNITION INTERLOCK USE 2 POSITION SPRING RETURN MOTOR WHITE LEADWIRES ON C7012 U V FLAME DETECTORS REPLACE C7012 BLACK WITH C7061 UV DETECTOR AND R7861A1026 AMPLIFIER iiq I MAKE SURE CONNECT
26. ONS AS RECEIVED INTERMITTENT PILOT SOLENOID MUST NOT EXCEED THE ELECTRICAL RATINGS OF TERMINAL 7 JR2 CLIPPED 15 SECOND INTERRUPTED PILOT JR2 CLIPPED TERMINALS 8 15 JUMPERED 30 SECOND INTERRUPTED PILOT M22608B Fig 8 Field wiring for R7140G1000 used for replacing R4140G Programmers with pre ignition interlocks 13 66 1153 03 R7140G L M BURNER CONTROL MODULES LED DISPLAY BURNER OPERATING CONTROLS AND INTERLOCKS FLAME SIGNAL FIRING RATE MOTOR 66 1153 03 R7140L INITIATE PREPURGE PREPURGE PFEP INITIAL HOLD HOLD 10 SEC POWERUP OOpRIVETO O TIMED 00 004 10 20 25 00 15 ONLY STANDBY HIGH FIRE PREPURGE LOWFIRE JR1 CLIPPED MFEP RUN STANDBY Power PoweR Power PowerR PowER PowerR Power PowER Power Power O O OPIiLor OPIitor PLoT O Q Q OFLAME OFLAME FLAME O O O O O Oman G ALARM QALARM OALARM OALARM QALARM O O BURNER BLOWER MOTOR IGN 5 SEC 1 10 SEC IGN PILOT 15 SEC PILOT 6 MAIN VALVE 7 LIMITS AND BURNER CONTROLLER CLOSED I I LOCKOUT INTERLOCKS CLOSED TO 3 N PII CLOSED 7X 5 HIGH FIRE SW SAFE START CHECK ssc SWITCHIN
27. OR IS ON TERMINAL 16 L2 REMOVE J1 AND J2 JUMPERS ON R7140M IF LOW FIRE SWITCH OR AJUMPER IS CONNECTED BETWEEN 8 AND 13 gt gt gt Fig 17 R7140M1007 used on applications replacing R4140M Programmers with Start Interlocks or BC7000 with PM720M 21 66 1153 03 R7140G L M BURNER CONTROL MODULES L FOR DIRECT SPARK IGNITION OIL OR GAS 2ND STAGE FUEL VALVE L L L L L L L L 1ST STAGE L L L L L OPTIONAL L FUEL VALVE 1 WIRING A 5 SECOND IGNITION SUBBASE RUNNING EARLY SPARK TERMINAL INTERLOCKS TERMINATION STRIP 4 INCLUDING AIRFLOW SWITCH 10 SECOND PREIGNITION INTERRUPTED INTERLOCKS PILOT IGNITION INTERMITTENT PILOT IGNITION MAIN FUEL VALVE S BURNER CONTROL MOTOR LOW FIRE SWITCH RECTIFYING FLAME A lt L1 HOT ROD OR 120V 60 HZ INFRARED POWER 4 12 LEAD SULFIDE SUPPLY MASTER FLAME DETECTOR SWITCH E I POWER SUPPLY PROVIDE DISCONNECT MEANS C1027 A OR WHITE E AND OVERLOAD PROTECTION AS REQUIRED CZOMA ULTRAVIOLET 1 FLAME DETECTOR A USE ALL NEC CLASS 1 WIRING WHEN USING 2 POSITION SPRING DAMPER MOTOR CLIP C7061 C7012A C YELLOW 1 AND REMOVE J1 AND J2 LOCATED ON R7140 SUBBASE ULTRAVIOLET FLAME DETECTOR FOR DIRECT SPARK IGNITION OIL OR GAS CONNECT THE IGNITION AND MAIN FUEL
28. PROGRAMMER WIRING PIVOT PIN 2 HINGE CHASSIS SUBBASE BRACKET 2 M22605 Fig 3 Mounting the programmer on the subbase R7140G L M BURNER CONTROL MODULES R7140G INITIATE PREPURGE PFEP INITIAL HOLD 10 SEC POWERUP COTIMED 004 sec 10 20 25 oo 12 ONLY STANDBY PREPURGE LOW FIRE JR1CLIPPED RUN POSTPURGE STANDBY POWER PowerR PowER Power PowER Power PoweR Power Power LED O O Optot Opiot piot QPro O DISPLAY O OFLAME FLAME FLAME O O O O MAIN O MAIN MAIN man van O O O OALARM QALARM OALARM QALARM QALARM Q BURNER OPERATING CONTROLS AND INTERLOCKS INTERLOCK CHECK SAFE START CHECK R7140G SWITCHING FIRING RATE MOTOR ACTION MOTOR B A TERMINAL 6 HAS THE FOLLOWING OPTIONS AS RECEIVED INTERMITTENT PILOT JR2 CLIPPED 15 SECOND MAIN FLAME ESTABLISHING PERIOD INTERRUPTED PILOT JR2 CLIPPED PLUS TERMINALS 8 15 JUMPERED 30 SECOND MAIN FLAME ESTABLISHING PERIOD INTERRUPTED PILOT A PII MEANS PRE IGNITION INTERLOCK A FOR R7140G1000 L1TO4 4TO3 Fig 4 Operating sequence R7140G1000 R7140G2008 M23319 66 1153 03 R7140G L M BURNER CONTROL MODULES L1 HOT L2 120 Vac 50 60 Hz CONFIGURATION CARB T JUMPERS FLAME SIGNAL JACK RUN TEST SWITCH RESET T PUSHBUTTON
29. R7140G L M Honeywell Burner Control Modules APPLICATION The Honeywell R7140G L M Burner Control Modules are microprocessor based integrated burner controls for automatically fired gas oil or combination fuel single burner applications The Burner Control Module system consists of a Relay Module Q520A Subbase Amplifier and Purge Card Options include S7800 Keyboard Display Modules KDM The R7140 Burner Control Modules directly replace many BC7000 PM720G L M and many R4150G L M and R4140G L M units using the existing Q520A 20 terminal Wiring Subbase The R7140 can be demonstrated or tested on the FSP5004 tester Note that the R7849 UV Amplifier or the R7851 Optical Flame Amplifier cannot be tested The R7140G L M is programmed to provide a level of safety functional capability and features beyond the capacity of conventional controls Functions provided by the R7140G L M include automatic burner sequencing flame supervision system status indication system or self diagnostics and troubleshooting INSTALLATION INSTRUCTIONS FEATURES Device status available to ModBus through S7810M card or S7800A1001 Series 5 Keyboard Display Safety features Interlock check Closed loop logic test Dynamic AMPLI CHECK M Dynamic input check Dynamic safety relay test Dynamic self check logic Expanded safe start check High Fire Purge Switch test R7140L only
30. RIOD JR2 CLIPPED AND JUMPER FROM 8 15 30 SECOND MAIN FLAME ESTABLISHING PERIOD A C7012E F NEEDS TO BE UPDATED TO C7061 M22607B Fig 7 Wiring diagram for R7140G2008 for application replacing R4140G with start Interlock or BC7000L1000 with PM720G 66 1153 03 12 R7140G L M BURNER CONTROL MODULES MAIN OIL VALVE SOLENOID A WIRING SUBBASE TERMINAL STRIP 4 RUNNING INTERLOCKS INCLUDING AIRFLOW SWITCH 10 SECOND INTERRUPTED PILOT IGNITION PILOT IGNITION MAIN FUEL VALVE S LOW FIRE SWITCH RECTIFYING FLAME ROD OR INFRARED LEAD SULFIDE FLAME DETECTOR MODULATE LOWFIRE 7044 ULTRAVIOLET 4 4 SERIES 90 SERIES 90 FLAME DETECTOR CONTROLLER FIRING RATE MOTOR C7067A D OR ELLO C7061 ULTRAVIOLET m ae 120V 60Hz L1 HOT POWER SUPPLY lt E MASTER SWITCH 12 FOR THE C7015A INFRARED LEAD SULFIDE FLAME DETECTOR EITHER A PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION LEADWIRE CAN BE CONNECTED TO THE F TERMINAL RUN THE C7015A AS REQUIRED LEADWIRES ALONE IN CONDUIT ALL THE WAY TO THE WIRING SUBBASE AND GROUND THE CONDUIT AT THE SUBBASE REFER TO PUBLICATION A USE ALL NEC CLASS 1 WIRING 60 2306 FOR DETAILED INSTRUCTIONS A FOR DIRECT SPARK IGNITION OF OIL CONNECT IGNITION TO A C7012 MUST BE UPDATED TO C7061 TERMINAL 5 AND MAIN OIL VALVE SOLENOID TO TERMINAL 7 JUMPER TERMINAL 7 TO TERMINAL 6 SEE INSET A TERMINAL 6 HAS THE FOLLOWING OPTI
31. RUN and also simulate a flame sig nal for 10 seconds to 30 seconds for PREPURGE b Flame LED is on c Safety shutdown occurs after 40 seconds 4 Failure to ignite pilot a Close pilot and main fuel manual shutoff valve s b Cycle burner on c Automatic pilot valve s should be energized but the pilot cannot ignite d Safety shutdown occurs 5 Failure to ignite main only interrupted pilot application a Open the manual pilot valve s leave the main fuel manual shutoff valve s closed b Depress the reset button c Start the system 33 R7140G L M BURNER CONTROL MODULES d The pilot should ignite and the flame signal should be at least 1 25 Vdc but the main burner cannot light e The flame signal should drop below 1 25 Vdc within the FFRT of the amplifier and the relay module after the interrupted pilot goes out f Safety shutdown occurs Loss of flame during RUN a Open the main fuel manual shutoff valve s and open manual pilot shutoff valve s b Depress the reset button c Start the system Start up should be normal and the main burner should light normally d After the sequence is in the normal RUN period for at least ten seconds with the main burner firing close the manual main fuel shutoff valve s to extinguish the main burner flame On intermittent pilot applications also close the pilot manual shutoff valve e The flame signal should drop below 1 25 Vdc within the FFRT of the amplif
32. VALVE S AS SHOWN IN THE INSET WHITE A FOR THE C7015A INFRARED LEAD SULFIDE FLAME DETECTOR EITHER 24 I LEADWIRE MAY BE CONNECTED TO THE F TERMINAL RUN THE C7015A LEADWIRES ALONE IN CONDUIT ALL THE WAY TO THE WIRING SUBBASE AND GROUND THE CONDUIT AT THE SUBBASE REFER TO PUBLICATION NOTE NUMBERS ON GP401 SUBBASE 60 2306 FOR DETAILED INSTRUCTIONS Awm SHUTTER LEADWIRES ARE ONLY ON THE C7061A OR F OR C7961 E OR F ULTRAVIOLET FLAME DETECTORS WITH SELF CHECKING FEATURE TERMINAL 17 IS NOT USED FOR OTHER DETECTORS REFER TO PUBLICATION 60 2358 FOR DETAILED INSTRUCTIONS REPLACEMENT R7140M START INTERLOCK BECOMES PRE IGNITION INTERLOCK M23338 Fig 18 Block diagram of field wiring for the R7140M1007 used for replacing R4140M Programmers with Pre Ignition Interlocks 66 1153 03 22 SAFETY SHUTDOWN Safety Shutdown Lockout occurs if any of the following occur during the indicated period 1 INITIATE Period a Purge card is not installed or is removed b Purge card is bad c Configuration jumpers are changed after 200 hours of operation d AC line power errors occur see Operation section e Four minute INITIATE period has been exceeded 2 STANDBY Period a Flame signal is present after 240 seconds b Pre lgnition Interlock is open an accumulative time of 30 seconds c Interlock check feature is enabled and the Interlock String including airflow switch is closed for 120 seconds with controller c
33. ct the manometer or pressure gauge and turn up the pilot gas flow to that recom mended by the equipment manufacturer If used remove the bypass jumpers from the subbase terminals limits controls or switches Run the system through another cycle to check for normal operation Return the system to normal operation 31 R7140G L M BURNER CONTROL MODULES IGNITION INTERFERENCE TEST ALL FLAME RODS Ignition interference can subtract from decrease or add to increase the flame signal If it decreases the flame signal enough it causes a safety shutdown If it increases the flame signal it could cause the FLAME LED to come on when the true flame signal is below the minimum acceptable value Start the burner and measure the flame signal with both ignition and pilot or main burner on and then with only the pilot or main burner on Any significant difference greater than 0 5 Vdc indicates ignition interference To Eliminate Ignition Interference 1 Make sure there is enough ground area 2 sure the ignition electrode and the flame rod are on opposite sides of the ground area 3 Check for correct spacing on the ignition electrode 6000V systems 1 16 to 3 32 in 1 6 to 2 4 mm b 10 000V systems 1 8 in 3 2 mm 4 Make sure the leadwires from the flame rod and ignition electrode are not too close together 5 Replace any deteriorated leadwires 6 Try wrapping the ignition wire with an insulated wire
34. cycle instead of opening the master switch allows purging the combustion chamber This reduces a buildup of fuel vapors in the combustion chamber caused by oil line purging 5 If the detector is sensing hot refractory correct the condition by one or more of the following procedures a Addan orifice plate in front of the cell to restrict the viewing area of the detector b Resight the detector at a cooler more distant part of the combustion chamber Make sure the detector properly sights the flame c Try lengthening the sight pipe or decreasing the pipe size diameter For details refer to the detector Instructions and the equipment Operating Manual Continue adjustments until hot refractory hold in is eliminated 66 1153 03 32 IGNITION SPARK RESPONSE TEST ALL ULTRAVIOLET DETECTORS Test to make certain that the ignition spark is not actuating the FLAME LED 1 Close the pilot and main burner manual fuel shut off valve s 2 Start the burner and use the Run Test Switch if available to stop the sequence in the PILOT IGN period Ignition spark should occur but the flame signal should not be more than 0 5 Vdc 3 Ifthe flame signal is higher than 0 5 Vdc and the FLAME LED does come on consult the equipment operating manual and resight the detector farther out from the spark or away from possible reflection It may be neces sary to construct a barrier to block the ignition spark from the detector view Cont
35. d to be installed in a device that can result in flammable gas or flammable liquid flow through a conduit or cable to an electrical ignition source in the event of a seal leakage or diaphragm failure This could be on the gas valves or gas or oil pressure regulators Check the Q520 Wiring Subbase terminals against the typical wiring drawings Figures 7 8 12 13 17 or 18 If wires are attached to terminals that are unused in the figures DO NOT INSTALL THE R7140 until you have identified the connections functions Most likely the old subbase terminals were used as tie points so removing the wires capping with a wire nut and tucking the wire down into the subbase is all that needs to be done R7140G L M BURNER CONTROL MODULES Make sure the wiring subbase of the old device is a 20 terminal Q520 four rows of 5 terminals Make sure the system Controller is connected to the correct terminal on the Q520 wiring subbase It may be in a wire nut tucked into the subbase It needs to be connected to a terminal like terminal 4 or 16 Make sure there is an electrical service ground wire connection to the G terminal in the wiring subbase R4140G or BC7000 with PM720G replacement Ifthe application was a dual burner ignition check the Q520 subbase for a jumper between terminals 6 to 7 discard the jumper and move the main valve connec tion terminal 7 to terminal 6 Replacing GP201 or GP301 devices High Fire or Purge Ra
36. e sure the ignition electrodes are clean Close the master switch and observe the spark 29 10 11 12 13 14 15 16 17 18 19 R7140G L M BURNER CONTROL MODULES g After a continuous spark is obtained open the master switch and add a jumper on the subbase from terminal L1 power to the pilot terminal 5 or 6 Reconnect the leadwire from the pilot valve if it was disconnected in step b h Close the master switch to energize both the ignition transformer and the pilot valve i If the pilot does not ignite and if the ignition spark is still continuous adjust the pressure regulator until a pilot is established j When the pilot ignites properly and stays ignited open the master switch and remove the jumper s from the terminals of the subbase k Check for adequate bleeding of the fuel line Reinstall the R7140 Relay Module on the subbase close the master switch and then return to step 4 When pilot ignites measure the flame signal If the pilot flame signal is unsteady or approaching the 1 25 Vdc minimum value adjust the pilot flame size or detector sighting to provide a maximum and steady flame signal Recycle the system to recheck lightoff and pilot flame signal When the MAIN LED turns on make sure the automatic main fuel valve is open then smoothly open the manual main fuel shutoff valve s and watch for main burner flame ignition When the main burner flame is establish
37. ed go to step 16 If the main burner flame is not established within five seconds or the normal lightoff time as specified by the equipment manufacturer close the manual main fuel shutoff valve s Recycle the system to recheck the lightoff and pilot flame signal Smoothly open the manual fuel shutoff valve s and try lightoff again The first re attempt may have been required to purge the lines and bring sufficient fuel to the burner If the main burner flame is not established within five seconds or the normal lightoff time specified by the equipment manufacturer close the manual main fuel shutoff valves s Check all burner adjustments If the main burner flame is not established after two attempts Check for improper pilot size Check for excess combustion air at Low Fire Check for adequate Low Fire fuel flow Check for proper gas supply pressure Check for proper valve operation Check for proper pilot flame positioning Repeat steps 8 and 9 to establish the main burner flame then go to step 16 With the sequence in RUN make burner adjustments for flame stability and Btu input rating Shut down the system by opening the burner switch or by lowering the setpoint of the operating controller Make sure the main flame goes out There may be a delay due to gas trapped between the valve s and burner Make sure all automatic fuel valve s close Restart the system by closing the burner switch and or raising
38. ier and the relay module after the main flame and or pilot goes out f R7140L goes to Safety Shutdown R7140G M recycle after 15 second postpurge g Safety shutdown occurs R7140L only Opening a Preignition Interlock after the first five seconds of POSTPURGE a Open the main fuel manual shutoff valve s and open manual pilot shutoff valve s b Depress the reset button c Preignition ILK fault is displayed on the Keyboard Display Module Fault code 33 is displayed to denote the fault d Safety shutdown occurs IMPORTANT 1 If the relay module fails to shut down on any of these tests take corrective action refer to Troubleshooting and the relay module diagnostics and return to the beginning of all Checkout tests 2 When all Checkout tests are completed reset all switches to the original status 66 1153 03 R7140G L M BURNER CONTROL MODULES 66 1153 03 34 35 R7140G L M BURNER CONTROL MODULES 66 1153 03 R7140G L M BURNER CONTROL MODULES Automation and Control Solutions Honeywell International Inc 1985 Douglas Drive North Golden Valley MN 55422 customer honeywell com U S Registered Trademark 2013 Honeywell International Inc 66 1153 03 M S Rev 01 13 Printed in United States Honeywell
39. inue adjustments until the flame signal due to ignition spark is less than 0 5 Vdc NOTE The Honeywell Q624A and Q652B Solid State Spark Generators prevent detection of ignition spark when properly applied with C7027 C7035 C7044 or C7061 Ultraviolet Flame Detectors The Q624A and Q652B are only for use with gas pilots Response To Other Ultraviolet Sources Some sources of artificial light such as incandescent or fluorescent bulbs mercury sodium vapor lamps and daylight produce small amounts of ultraviolet radiation Under certain conditions an ultraviolet detector responds to these sources as if itis sensing a flame To check for proper detector operation check the Flame Failure Response Time FFRT and conduct Safety Shutdown Tests under all operating conditions Flame Signal With Hot Combustion Chamber All Installations 1 With all initial start up tests and burner adjustments com pleted operate the burner until the combustion chamber is at the maximum expected temperature 2 ObDserve the equipment manufacturer warm up instructions 3 Recycle the burner under these hot conditions and measure the flame signal Check the pilot alone the main burner flame alone and both together unless monitoring only the pilot flame when using an intermittent pilot or only the main burner flame when using DSI Check the signal at both High and Low Firing Rate positions and while modulating if applicable 4 Checkthe FFRT of the f
40. ion before leaving the installation R7140G L M BURNER CONTROL MODULES SETTINGS AND ADJUSTMENTS Selectable Site Configurable Jumpers The R7140 has three site configurable jumper options see Fig 19 and Table 7 If necessary clip the site configurable jumpers with side cutters and remove the resistors from the Relay Module The R7140M has two additional jumpers located on the back of the chassis These must be cut if a spring return damper motor is used SELECTABLE CONFIGURATION JUMPERS Z RUN TEST SWITCH JUMPERS PILOT FLAME JR1 EST PERIOD INTACT 10 SEC PILOT OPER AMB TEMP INTERMIT INTERRUPT JR2 vave 40 140 F JR3 DISABLED ENABLED 40 TO 60 C LESRISQUES USE PROPERTY DAMAGE D EXPLOSION SEVERE INJURY OR DEATH DES DOMMAGES GRAVES x asit avant le br leur NOTE CONFIGURATION JUMPERS SHOWN FOR RM7800G RM7840G M12301 Fig 19 Selectable site configurable jumpers Table 7 Site Configurable Jumper Options Jumper Number Description Intact Clipped RM7800 RM7840 Type Pilot Flame Establishing 10 seconds 4 seconds All Period PFEP JR2 Pilot Valve Main Flame 10 seconds 15 30 seconds Interrupted R7140G Establishing Period MFEP Intermittent JR3 Start up Interlock Check Disabled Enabled All 8 Pilot Valve First Stage Oil Valve Valve Start terminal 6 b A 30 second MFEP can be accomplished by adding
41. ks Burner Switch Run Test Switch Lockout Interlocks and all microcomputer monitored circuits must be in the correct operating state b The blower motor output terminal 8 is powered to start the PREPURGE sequence The PREPURGE timing for the R7140L does not begin until the High Fire Switch is closed NOTE A jumpered High Fire Switch adds a 30 second hold before the purge time starts c The Pre Ignition Interlock input must remain closed throughout PREPURGE otherwise control returns to the STANDBY state and holds 30 seconds for the R7140G M or safety shutdown for the R7140L occurs d The Lockout Interlock or Running Interlock inputs interlock circuit including Airflow Switch must close by ten seconds into PREPURGE otherwise a recycle to the beginning of PREPURGE for the R7140G M will happen or a safety shutdown for the R7140L occurs e When PREPURGE timing is complete the firing rate motor drives to the low fire position If a damper motor is used R7140M jumpers J1 and J2 should be removed from R7140 subbase f When the firing rate motor reaches low fire position the Low Fire Switch terminal 13 is energized to enter the Ignition Trial state NOTE 30 hold occurs for a jumpered Low Fire Switch before the ignition trial period begins Ignition Trials 1 Pilot Flame Establishing Period PFEP a With the firing rate motor at the low fire position 1 The pilot valve and ignition transformer
42. lame amplifier and relay module 5 Lower the setpoint of the operating controller and observe the time it takes for the burner flame to go out This should be within the maximum FFRT 6 If the flame signal is too low or unsteady check the flame detector temperature Relocate the detector if the temper ature is too high 7 f necessary realign the sighting to obtain the proper sig nal and response time 8 If the response time is still too slow replace the Plug in Flame Signal Amplifier 9 If the detector is relocated or resighted or the amplifier is replaced repeat all required Checkout tests SAFETY SHUTDOWN TESTS ALL INSTALLATIONS Perform these tests at the end of Checkout after all other tests are completed If used the external alarm should turn on Press the RESET pushbutton on the relay module to restart the system 1 Opening a Preignition Interlock during the STANDBY PREPURGE period R7140L Lockout R7140G and M Standby Hold 40 seconds then Lockout a Safety shutdown occurs 2 Opening a Lockout Interlock during PREPURGE PILOT IGN MAIN IGN or RUN period R7140L Only a R7140G and R7140M go to Standby b Safety shutdown occurs 3 Detection of flame 40 seconds after entry to STANDBY from RUN Detection of flame from ten seconds up to 30 seconds into PREPURGE time a Simulate a flame to cause the flame signal voltage level to be at least 1 25 Vdc for 40 seconds after entry to STANDBY from
43. language 57800 1126 Portuguese language Pre Purge Timing Product Number 57800 1142 English language 7 ST7800A1013 ad Communications 0 ST7800A1039 7810 1009 Data ControlBus Module if is 40 ST7800A1047 used 57810 1003 ModBus Module 60 ST7800A1054 Miscellaneous 90 ST7800A1062 S7820A1007 Remote Reset Module S7830A1005 Expanded Annunciator 120 Vac 50 60 Hz Above times cover the Purge timings of the R4140 50 Pro 203541 Data ControlBus Connector 5 wire grammers and PM720 203765 Remote Display Mounting Bracket Other timings exist consult the Tradeline catalog for com 221729 Dust cover Relay Module plete list of ST7800 Purge timers 50023821 001 Keyboard Display Module Cover NEMA 4 clear Accessories 50023821 002 Keyboard Display Module Cover NEMA 4 The following accessories enhance the R7140 Burner Control clear with reset button Module and are available through local 7800 SERIES 205321 Flush Display mounting kit distributors 221818A Extension Cable display 5 ft 1524 mm Keyboard Display Modules KDM 221818C Extension Cable display 10 ft 3048 mm 57800 1001 English language FSP5004 Tester 7800 1035 French language 123514A Rectification Flame Simulator 57800 1043 German language 203659 Ultraviolet Flame Simulator 57800 1050 Italian language 6 5 32 156 1 1 4 ee 32 127 5 3 4 146 an Fig 2 Mounting dimensions of R7140G L M B
44. lose the manual main fuel shutoff valve s Connect a manometer or pressure gauge to measure pilot gas pressure during the turndown test Open the manual pilot shutoff valve s Close the master switch and start the system with a call for heat Raise the setpoint of the operating controller The 7800 Series sequence should start and PRE PURGE if applicable should begin aw After the PILOT LED turns on in interrupted pilot applications set the Run Test Switch to the TEST position to stop the sequence The FLAME LED comes on when the pilot ignites NOTE If the sequence does not stop reset the system and make sure you set the Run Test Switch to TEST within the first eight seconds of the PILOT IGN sequence IMPORTANT You have 0 8 second or three seconds depending on PFEP selected to position the Run Test Switch to the TEST position to stop the sequence after the start of the PILOT IGN period Turn down the pilot pressure very slowly reading the manometer or pressure gauge as it drops Stop instantly when the FLAME LED goes out Note the pressure The pilot is at the minimum turndown position Immediately turn up the pilot pressure until the FLAME LED comes on again or the flame signal increases to 1 25 Vdc NOTE If there is no flame for 15 seconds with the 10 RUN TEST switch in the TEST position the relay module locks out Repeat step 7 to verify the pilot gas pressure reading at the exact point the F
45. losed d Ignition pilot valve intermittent pilot valve terminal is energized e Main valve terminal is energized f Internal system fault occurs g Purge card is not installed or is removed h Purge card is bad PREPURGE Period Pre Ignition Interlock opens anytime during PRE PURGE period R7140L b Flame signal is detected after first ten seconds during PREPURGE R7140L c High Fire Switch fails to close within 4 minutes and 15 seconds after the firing rate motor is commanded to drive to the high fire position at the start of PRE PURGE R7140L d Low Fire Switch fails to close within 4 minutes and 15 seconds after the firing rate motor is commanded to drive to the low fire position at the end of PRE PURGE e Running Interlock does not close within 30 seconds R7140G M f Lockout Interlock does not close within 10 seconds R7140L g Lockout Interlock opens during PREPURGE R7140L h Ignition pilot valve intermittent pilot valve terminal is energized i Main valve terminal is energized j Internal system fault occurs k Purge card is removed l Purge card is bad 4 PILOT FLAME ESTABLISHING Period PFEP a Low Fire Switch opens b Lockout Interlock opens RM7140L c Ignition pilot valve intermittent pilot valve terminal is not energized d Early spark termination terminal is energized after five seconds No flame is present at the end of PFEP Main valve terminal is energized R7140G M
46. mage 27 66 1153 03 R7140G L M BURNER CONTROL MODULES SYSTEM CHECKOUT IMPORTANT Perform all Static Checkout Procedures for the applicable relay module shown in Table 8 before starting these procedures A WARNING Explosion Hazard Can cause serious injury or death Do not allow fuel to accumulate in the combustion chamber for longer than a few seconds without igniting to prevent danger of forming explosive mixture Close manual fuel shutoff valve s if flame is not burning at end of specified time A WARNING Electric Shock Hazard Can cause serious injury or death 1 Use extreme care while testing system Line voltage is present on most terminal connections when power is on 2 Open master switch before removing or installing R7140 Relay Module Make sure all manual fuel shutoff valve s are closed before starting initial lightoff check and Pilot Turndown tests Do not put the system in service until you have satisfactorily completed all applicable tests in this section and any others recommended by the original equipment manufacturer Limit trial for pilot to ten seconds Limit the attempt to light main burner to two seconds after fuel reaches burner nozzle Do not exceed manufacturer nominal lightoff time N CAUTION Equipment Malfunction or Damage Hazard Incorrect wiring can cause equipment damage Each relay module type is unique Using existing wiring on a relay module change can cause equi
47. may cause interference in which case the users at their own expense may be required to take whatever measures are required to correct this interference 10 This digital apparatus does not exceed the Class A limits for radio noise for digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications Location Humidity Install the relay module where the relative humidity never reaches the saturation point The relay module is designed to operate in a maximum 85 percent relative humidity continuous noncondensing moisture environment Condensing moisture may cause a safety shutdown Vibration Do not install the relay module where it could be subjected to vibration in excess of 0 5G continuous maximum vibration Weather The relay module is not designed to be weathertight When installed outdoors protect the relay module using an approved weathertight enclosure Wiring Check Check the power supply circuit The voltage and frequency tolerance must match those of the R7140 A separate power supply circuit may be required for the R7140 Add the required disconnect means and overload protection 2 Check all wiring circuits and complete the Static Checkout Table 8 before installing the R7140 on the subbase 3 Install all electrical connectors 4 Restore power to the panel Service Notes Per industry standards a conduit seal or a cable type that is sealed is require
48. nal screws are tight 2 Flame detector s is clean installed and positioned properly Consult the applicable Instructions 66 1153 03 3 Combination of amplifier and flame detector s is correctly used See the amplifier specifications 4 Plug in amplifier and purge card if required are securely in place 5 Burner is completely installed and ready to fire consult equipment manufacturer instructions Fuel lines are purged of air 6 Combustion chamber and flues are clear of fuel and fuel vapor 11 Power is connected to the system disconnect switch master switch Lockout is reset reset button only if the Relay Module is powered Run Test Switch if present is in RUN position System is in STANDBY condition STANDBY message is displayed in the S7800 Keyboard Display Module All limits and interlocks are reset Flame Signal Measurement See instructions provided with the amplifier INITIAL LIGHTOFF CHECKS Proved Pilot Systems Perform this check on all installations that use a pilot It should immediately follow the preliminary inspection NOTE Low fuel pressure limits if used could be open If so bypass them with jumpers during this check Open the master switch Make sure that the manual main fuel shutoff valve s is closed Open the manual pilot shutoff valve If the pilot takeoff is downstream from the manual main fuel shutoff valve s slightly open the manual main valve to supply pilot
49. oO MICROCOMPUTER RESET x PUSHBUTTON O O TEST AMPLIFIER RELAY DRIVE RELAY CIRCUIT STATUS FEEDBACK 2 AND LINE 5 VOLTAGE o _ INPUTS o o SAFETY RELAY 1K CIRCUIT STATUS LEDs CONTROL POWER SUPPLY POWER PRE IGNITION INTERLOCK mx 4 RUNNING LOCKOUT LIMITS CONTROLLER INTERLOCK ad pa aes HH IGNITION 16 3 18 IGNITION LOW FIRE SWITCH 5 PILOT nu 6 PILOT V2 HIGH FIRE SWITCH 15 HH 7 MAIN VALVE 6K1 8 BLOWER 3K1 9 ALARM KEYBOARD DISPLAY MODULE DDL 2 a Remote 92 COMMUNICATIONS RESET 8K1 COMMON t INDICATES FEEDBACK SENSING OF RELAY CONTACT STATUS AND LINE VOLT INPUTS HIGH FIRE 9 1 8 2 MODULATE 9K1 LOW FIRE FIELD WIRING INTERNAL WIRING PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED M23329 Fig 11 Internal block diagram of the R7140L2007 See Fig 13 for detailed wiring 66 1153 03 16 R7140G L M BURNER CONTROL MODULES IGNITION TRANSFORMER MAIN FUEL VALVE A 5 SECOND IGNITION WIRING EARLY SPARK SUBBASE LOCKOUT TERMINATION TERMINAL INTERLOCKS STRIP 4 INCLUDING AIRFLOW SWITCH 10 SECOND INTERRUPTED PREIGNITION PILOT IGNITION INTERLOCKS 15 SECOND INTERRUPTED PILOT IGNITION MAIN FUEL VALVE S RECTIFYING FLAME ROD OR INFRARED LEAD SULFIDE FLAME DETECTOR C7027A C7035A OR
50. off valves are closed before performing static checkout 1 Voltmeter 1M ohm volt minimum sensitivity set on the 0 300 Vac scale 2 Two jumper wires no 14 wire insulated 12 inches 304 8 mm long with insulated alligator clips at both ends Table 8 Static Checkout Test Test If Operation is Abnormal No R7140 Models Jumpers Voltmeter Normal Operation Check the Items Listed Below 1 All None L1 L2 Line voltage at terminal L1 1 Master Switch 2 Power connected to the Master Switch 3 Overload protection fuse circuit breaker etc has not opened the power line 2 16 L2 Line voltage at terminal 16 4 on 1 Limits Pre Ignition Interlock devices 2 Burner Controller 3 4 L2 Line voltage at terminal 16 1 Pre Ignition interlocks 4 L1 8 3 L2 1 Burner motor fan or 1 Burner motor circuit blower starts a Manual switch of burner motor 2 Line voltage at terminal 3 b Burner motor power supply overload within 10 seconds protection and starter c Burner motor 2 Running or Lockout Interlocks including Airflow Switch 5 L1 18 Ignition spark if ignition 1 Watch for spark or listen for buzz transformer is connected to a Ignition electrodes are clean terminal 18 b Ignition transformer is okay 66 1153 03 26 R7140G L M BURNER CONTROL MODULES Table 8 Static Checkout Continued Test Test If Operation is Abnormal No R7140 Models Jumpers Voltmeter
51. pment damage IMPORTANT 1 If the system fails to perform properly refer to the Troubleshooting section 2 Repeat all required Checkout tests after all adjustments are made All tests must be satisfied with the flame detector s in their final position Equipment Recommended S7800A Keyboard Display Module Volt ohmmeter 1M ohm volt minimum sensitivity with 0 300 Vac capability 0 6000 ohm capability 0 10 capability Checkout Summary Table 9 provides an overview of checkout steps performed for each applicable system See Installation Instructions for location of component parts and terminal locations Table 9 Checkout Steps and Applicable Detection Systems Piloted Infrared Flame Flame Rod Ultraviolet Checkout Step Systems DSI Systems Detectors Systems Flame Detectors Preliminary Inspection X X X X X Flame Signal Measurement X X X X X Initial Lightoff Check for Proved Pilot X Initial Lightoff Check for Direct Spark Ignition X Pilot Turndown Test X Ignition Interference Test X Hot Refractory Saturation Test X Hot Refractory Hold in Test X X X X X Ignition Spark Pickup X Response to Other Ultraviolet Sources X Flame Signal with Hot Combustion Chamber X X X X X Safety Shutdown Tests X X X X x Preliminary Inspection Perform the following inspections to avoid common problems Make certain that 1 Wiring connections are correct and all termi
52. s close Goto step 19 Restart the system by closing the burner switch and or raising the setpoint of the operating controller Observe that the burner flame is established during PILOT IGN within the normal lightoff time specified by the equipment manufacturer Measure the flame signal Continue to check for the proper signal through the RUN period Check the signal at both high and low firing rate positions and while modulating Any pulsating or unsteady readings require further attention Make sure all readings are in the required ranges before proceeding 17 18 20 21 NOTE On completing these tests open the master switch and remove all test jumpers from the subbase terminals limits controls or switches 22 Return the system to normal operation PILOT TURNDOWN TEST ALL INSTALLATIONS USING A PILOT Perform this check on all installations that use a pilot The purpose of this test is to verify that the main burner can be lit by the smallest pilot flame that can hold in the flame amplifier and energize the FLAME LED Clean the flame detector s to make sure that it detects the smallest acceptable pilot flame If using AMPLI CHECK or self checking amplifier and 1M ohm volt meter the flame signal fluctuates every time the amplifier does a self check or a shutter check NOTE Low fuel pressure limits if used could be open If so bypass them with jumpers during this test Open the master switch C
53. so enter the INITIATE sequence if the Relay Module verifies voltage fluctuations of 10 15 percent or frequency fluctuations of 10 percent during any part of the operating sequence The INITIATE sequence lasts for ten seconds unless the voltage or frequency tolerances are not met When the tolerances are not met a hold condition is initiated for at least five seconds When the tolerances are met the INITIATE sequence restarts If the condition is not corrected and the hold condition exists for four minutes the R7140 locks out Causes for hold conditions in the INITIATE sequence a AC line dropout is detected b AC line noise prevents a sufficient reading of the line voltage inputs c Low line voltage brownouts occur The INITIATE sequence also delays the burner motor starter from being energized and de energized from an intermittent AC line input or control input Standby The R7140 is ready to start an operating sequence when the operating control determines a call for heat is present The burner switch limits operating control and all microcomputer monitored circuits must be in the correct state for the R7140 to continue into the PREPURGE sequence 66 1153 03 R7140G L M BURNER CONTROL MODULES Normal Start Up Pre Purge The R7140 provides a pre purge timing selectable from two seconds to 30 minutes with power applied and the R7140 operating control indicating a call for heat a Running Interlocks Pre Ignition Interloc
54. stage burner flame is not established within four seconds or within the normal lightoff time specified by the equipment manufacturer close the manual fuel shutoff valve s and open the master switch If necessary repeat steps 11 through 13 to establish the first stage burner flame Then go to step 15 When the first stage burner flame is established the sequence advances to RUN Make burner adjustments for flame stability and input rating If a second stage is used go to step 18 5 11 12 13 14 15 66 1153 03 30 16 Shut down the system by opening the burner switch by lowering the setpoint of the operating controller Make sure the burner flame goes out and all automatic fuel valves close If used remove the bypass jumpers from the low fuel pressure limit and subbase If a second stage is used make sure the automatic second stage fuel valve s opened Check the lightoff as follows or go to step 19 a Open the manual second stage fuel valve s b Restart the system by raising the setpoint of the operating controller c When the first stage burner flame is established watch for the automatic second stage fuel valve s to open Observe that the second stage lights off properly d Make burner adjustments for flame stability and input rating e Shut down the system by lowering the setpoint of the operating controller Make sure the burner flame goes out and all automatic fuel valve
55. supply and equipment as recommended by the equipment manufacturer 3 Close all manual main fuel shutoff valve s Check that the automatic fuel valve s is closed Make sure fuel is not entering the combustion chamber 4 Close the master switch and start the system with a call for heat by raising the setpoint of the operating controller see the relay module sequencing The program sequence should start the INITIATE sequence 5 Let the sequence advance through PREPURGE if applicable Ignition spark should occur when the PILOT LED turns on Listen for the click of the first stage fuel solenoid valve s The relay module locks out and the ALARM LED turns on Let the R7140 Relay Module complete its cycle Open the manual fuel shutoff valve s Push the reset button and the relay module recycles the program sequence through PREPURGE if applicable When the PILOT LED turns on make sure that the first stage burner flame is established If it is go to step 15 If the first stage burner flame is not established within four seconds or within the normal lightoff time specified by the equipment manufacturer close the manual fuel shutoff valve s and open the master switch Check all burner adjustments Wait about three minutes Close the master switch open the manual fuel shutoff valve s and try to light off the burner again The first attempt may be required to purge the lines and bring sufficient fuel to the burner If the first
56. t of an internal short circuit The R7140 needs a low impedance ground connection to the equipment frame which in turn needs a low impedance connection to earth ground Table 4 Terminal Ratings Terminal Typical Load Maximum Rating at 120 Vac 60 Hz 5or6 Ignition 4 5A ignition and 50 VA pilot duty or Transformer Pilot 2 5A ignition and 75 VA pilot duty Valve First Stage Fuel Valve 7 Main Fuel Valve s solenoid 250 VA pilot duty or 65 VA pilot duty in parallel with motorized valve s using a total of motorized diaphragm and 1150 VA locked rotor inrush 460 VA to open and 250 VA to hold or motorized valve s Vent Valve if required using a total of 1500 VA locked rotor inrush 600 VA to open and 250 VA to hold 66 1153 03 R7140G L M BURNER CONTROL MODULES Table 5 Sequence Timing for Normal Operation Flame Establishing Period Device Initiate Standby Purge Pilot Main Run R7140G 10 sec 140 10 10 15 sec sec intermittent R7140L 10 15 sec R7140M 10 sec or intermittent Post Purge Timing 15 sec Firing Energy Approval Rate Saving Code Interlock Circuits Circuit Pre Purge Bodies Pre Ignition 4 wire No UL CSA Running Low Fire modulating Modulating Pre Ignition FM IRI Lockout High and Modulating Low Fire Pre Ignition 2 wire UL CSA Running isolated isolated On Off Low Fire On Off On
57. te Switch may be connected to terminal D Identify remove and connect to terminal M Replacing GP101 devices Check wiring subbase If D is jumpered to 8 remove the jumper Replacing R4140 programmers on Carlin 1050 and 1150 burners Remove jumper from 6 to 7 Remove jumper from L2 to 12 and wire nut the wires together Note There will be no wire on terminal 12 R4140M replacements Check terminal 13 of the Q520 wiring subbase f nothing is on 13 install the new R7140M1007 f 18 is jumpered to 8 remove the jumper and install R7140M1007 f 13 goes somewhere assume a low fire switch because the system has a damper motor remove J1 and J2 from the back of the R7140M1007 NOTE J1 and J2 provide an input for the R7140M when the system does not have a spring return damper with a low fire switch Leaving J1 and J2 in place with either 13 jump ered to 8 or with the low fire switch will cause the blower motor to come on after the R7140M is installed and power is supplied to the system Generally the following table will apply to select the R7140M1007 model and the status of jumpers J1 and J2 66 1153 03 R7140G L M BURNER CONTROL MODULES Table 6 J1 J2 Jumper Configuration for R4140M PM720M Model Purge Timer Leave J1 amp J2 Remove J1 and J2 R4140M1004 M1012 A1039 X R4140M1020 M1038 A1047 X R4140M1046 M1053 A1062 X R4140M1079 GP101 A
58. ted on the top side of the R7140 see Fig 1 The Run Test Switch allows the burner sequence to be altered as follows NOTE In Pre Purge Drive To High Fire Position R7140L the Run Test Switch when placed in the TEST position holds in PREPURGE with the firing rate motor in the High Fire position In the measured PREPURGE sequence the Run Test Switch when placed in the TEST position causes the PREPURGE timing to stop The firing rate motor is in the High Fire position In Pre Purge Drive to Low Fire position the Run Test Switch when placed in the TEST position holds the burner sequence in PREPURGE with the firing rate motor in the Low Fire position In PFEP the Run Test Switch when placed in the TEST position stops the timer during the first 8 seconds when a 10 second PFEP is selected or during the first 3 seconds when a 4 second PFEP is selected allowing pilot turn down test and other burner adjustments to be made This activates a 15 second flameout timer that permits pilot flame adjustment without nuisance safety shutdowns The Run Test Switch is ignored during PFEP for the R7140L if terminals 5 and 7 or 7 and 6 are jumpered During Run the Run Test Switch when placed in the TEST position drives the firing rate motor to the Low Fire position When R7140 is switched to the Test mode it stops and holds at the next Run Test Switch point in the operating sequence Make sure that the Run Test Switch is in the RUN posit
59. unique therefore refer to Fig 4 11 or the correct Specifications for proper subbase wiring and sequence charts Wiring must comply with all applicable codes ordinances and regulations Wiring must comply with NEC Class 1 Line Voltage wiring Loads connected to the R7140 must not exceeq those listed in the Specifications see Table 3 and 4 Limits and interlocks must be rated to simultaneously carry and break current to the ignition transformer pilot valve and main fuel valve s All external timers must be listed or component recognized by authorities who have jurisdiction for the specific purpose for which they are used For on off gas fired systems some authorities who have jurisdiction prohibit the wiring of any limit or operating contacts in series between the flame safeguard control and the main fuel valve s Two Flame Detectors can be connected in parallel with the exception of flame detectors C7927 C7915 C7961 and C7962 This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause interference to radio communications It has been tested and found to comply with the limits for a Class A computing device of Part 15 of FCC rules which are designed to provide reasonable protection against such interference when operated in a commercial environment Operation of this equipment in a residential area
60. urner Control Module with Q520A Subbase in in mm M22604 66 1153 03 4 R7140G L M BURNER CONTROL MODULES Table 3 Terminal Ratings Terminal No Description Ratings G Flame Sensor Earth Ground Earth G Earth Ground L2 N Line Voltage Common L1 Line Voltage Supply L1 120 Vac 10 15 50 or 60 Hz 10 3 Lockout Running Interlock 120 Vac 8A run 43A inrush 4 Pre Ignition Interlock Input 120 Vac 1 mA 5 Pilot Valve Ignition 120 Vac See Table 4 6 Interrupted Intermittent Pilot Valve First Stage Oil Valve 120 Vac See Table 4 7 Main Fuel Valve 120 Vac See Table 4 8 Burner Motor 120 Vac 9 8 AFL 58 8 ALR inrush 9 Alarm 120 Vac 1A pilot duty 10 Firing Rate High Fire 120 Vac 75 VA pilot duty 11 Firing Rate Common 120 Vac 75 VA pilot duty 12 Firing Rate Modulate 120 Vac 75 VA pilot duty 13 Low Fire Switch Input 120 Vac 1 mA 14 Firing Rate Low Fire 120 Vac 75 VA pilot duty 15 High Fire Switch Input 120 Vac 1 mA 16 Burner Controller and Limits 120 Vac 1 mA 17 Shutter 120 Vac 0 5A 18 Ignition 120 Vac 4 5A ignition F Flame Sensor 60 to 220 Vac current limited The R7140 must have an earth ground providing a connection between the subbase and the control panel or the equipment The earth ground wire must be capable of conducting the current to blow the 15A fast blow fuse or breaker in the even

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